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Hydraulic system leaks: causes and fixes

A small weep can cause pressure loss, hot oil and pump damage. Learn where leaks usually start and how to fix them for good.

Hydraulic system leaks: causes and fixes

Hydraulics on reach stackers, cranes and construction machines run at high pressure. Leaks waste oil, create slip hazards, reduce lifting force and contaminate the system.

Common leak points

  • Fittings: wrong torque, damaged threads, mixed standards (JIC, ORFS, BSP…).
  • Hoses: ageing, abrasion, bending below the minimum radius.
  • Cylinder seals: scored rods, dirty oil, wrong seal material.
  • Pumps, motors, valves: worn shafts, failed shaft seals.

Fixing it properly

  1. Release system pressure first – never feel for leaks by hand under pressure.
  2. Clean the area to find the exact source.
  3. Replace fittings, hoses or seals with the correct standard and material.
  4. Check oil cleanliness and change the return filter if needed.
  5. Test run and re-check after a few working hours.

Prevention

Route hoses away from rubbing points, use correctly sized clamps, replace hoses by age and check for leaks at every service. TTT supplies hydraulic parts: pumps, motors, cylinders, valves, hoses and fittings.

Need advice or a quote? Send the part number or a photo of the nameplate through our quote form or call 0909 580 181 – TTT engineers reply within the working day.

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